WO2004096127A2 - Formation of strong superporous hydrogels - Google Patents

Formation of strong superporous hydrogels Download PDF

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Publication number
WO2004096127A2
WO2004096127A2 PCT/US2004/011448 US2004011448W WO2004096127A2 WO 2004096127 A2 WO2004096127 A2 WO 2004096127A2 US 2004011448 W US2004011448 W US 2004011448W WO 2004096127 A2 WO2004096127 A2 WO 2004096127A2
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Prior art keywords
hydrogel
supeφorous
cations
mixture
cation
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PCT/US2004/011448
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English (en)
French (fr)
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WO2004096127A3 (en
Inventor
Hossein Omidian
Jose Gutierrez-Rocca
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Kos Life Sciences, Inc.
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Priority to JP2006510012A priority Critical patent/JP4869066B2/ja
Priority to AU2004233805A priority patent/AU2004233805B2/en
Priority to CA002523246A priority patent/CA2523246C/en
Priority to EP04750099A priority patent/EP1620076A4/en
Priority to MXPA05011311A priority patent/MXPA05011311A/es
Publication of WO2004096127A2 publication Critical patent/WO2004096127A2/en
Publication of WO2004096127A3 publication Critical patent/WO2004096127A3/en

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    • C08F251/00—Macromolecular compounds obtained by polymerising monomers on to polysaccharides or derivatives thereof
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/14—Macromolecular materials
    • A61L27/20—Polysaccharides
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/50—Materials characterised by their function or physical properties, e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
    • A61L27/52—Hydrogels or hydrocolloids
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L27/00—Materials for grafts or prostheses or for coating grafts or prostheses
    • A61L27/50—Materials characterised by their function or physical properties, e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
    • A61L27/56—Porous materials, e.g. foams or sponges
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L31/00—Materials for other surgical articles, e.g. stents, stent-grafts, shunts, surgical drapes, guide wires, materials for adhesion prevention, occluding devices, surgical gloves, tissue fixation devices
    • A61L31/04—Macromolecular materials
    • A61L31/042—Polysaccharides
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L31/00—Materials for other surgical articles, e.g. stents, stent-grafts, shunts, surgical drapes, guide wires, materials for adhesion prevention, occluding devices, surgical gloves, tissue fixation devices
    • A61L31/14—Materials characterised by their function or physical properties, e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
    • A61L31/145—Hydrogels or hydrocolloids
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61L—METHODS OR APPARATUS FOR STERILISING MATERIALS OR OBJECTS IN GENERAL; DISINFECTION, STERILISATION OR DEODORISATION OF AIR; CHEMICAL ASPECTS OF BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES; MATERIALS FOR BANDAGES, DRESSINGS, ABSORBENT PADS OR SURGICAL ARTICLES
    • A61L31/00—Materials for other surgical articles, e.g. stents, stent-grafts, shunts, surgical drapes, guide wires, materials for adhesion prevention, occluding devices, surgical gloves, tissue fixation devices
    • A61L31/14—Materials characterised by their function or physical properties, e.g. injectable or lubricating compositions, shape-memory materials, surface modified materials
    • A61L31/146—Porous materials, e.g. foams or sponges
    • C—CHEMISTRY; METALLURGY
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    • C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
    • C08F2/00—Processes of polymerisation
    • C08F2/44—Polymerisation in the presence of compounding ingredients, e.g. plasticisers, dyestuffs, fillers
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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    • C08F251/00—Macromolecular compounds obtained by polymerising monomers on to polysaccharides or derivatives thereof
    • C08F251/02—Macromolecular compounds obtained by polymerising monomers on to polysaccharides or derivatives thereof on to cellulose or derivatives thereof
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    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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    • C08F8/00—Chemical modification by after-treatment
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    • C08J3/00—Processes of treating or compounding macromolecular substances
    • C08J3/02—Making solutions, dispersions, lattices or gels by other methods than by solution, emulsion or suspension polymerisation techniques
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    • C08J3/075—Macromolecular gels
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    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/04—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent
    • C08J9/06—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a chemical blowing agent
    • C08J9/08—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof using blowing gases generated by a previously added blowing agent by a chemical blowing agent developing carbon dioxide
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    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/28—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof by elimination of a liquid phase from a macromolecular composition or article, e.g. drying of coagulum
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    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
    • C08J9/36—After-treatment
    • C08J9/40—Impregnation
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2201/00—Foams characterised by the foaming process
    • C08J2201/02—Foams characterised by the foaming process characterised by mechanical pre- or post-treatments
    • C08J2201/024—Preparation or use of a blowing agent concentrate, i.e. masterbatch in a foamable composition
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2201/00—Foams characterised by the foaming process
    • C08J2201/04—Foams characterised by the foaming process characterised by the elimination of a liquid or solid component, e.g. precipitation, leaching out, evaporation
    • C08J2201/054—Precipitating the polymer by adding a non-solvent or a different solvent
    • C08J2201/0545—Precipitating the polymer by adding a non-solvent or a different solvent from an aqueous solvent-based polymer composition
    • C08J2201/0546—Precipitating the polymer by adding a non-solvent or a different solvent from an aqueous solvent-based polymer composition the non-solvent being organic
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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    • C08J2203/00—Foams characterized by the expanding agent
    • C08J2203/02—CO2-releasing, e.g. NaHCO3 and citric acid
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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    • C08J2205/00—Foams characterised by their properties
    • C08J2205/02—Foams characterised by their properties the finished foam itself being a gel or a gel being temporarily formed when processing the foamable composition
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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    • C08J2205/00—Foams characterised by their properties
    • C08J2205/02—Foams characterised by their properties the finished foam itself being a gel or a gel being temporarily formed when processing the foamable composition
    • C08J2205/022—Hydrogel, i.e. a gel containing an aqueous composition
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    • C08J2300/00—Characterised by the use of unspecified polymers
    • C08J2300/14—Water soluble or water swellable polymers, e.g. aqueous gels
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    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
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    • C08J2301/00—Characterised by the use of cellulose, modified cellulose or cellulose derivatives
    • C08J2301/08—Cellulose derivatives
    • C08J2301/26—Cellulose ethers
    • C08J2301/28—Alkyl ethers
    • C—CHEMISTRY; METALLURGY
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    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L2205/00—Polymer mixtures characterised by other features
    • C08L2205/04—Polymer mixtures characterised by other features containing interpenetrating networks

Definitions

  • the present invention relates to a method for the formation of supe ⁇ orous hydrogels having improved physical and mechanical properties.
  • Supe ⁇ orous hydrogels are chemically crosslinked hydrophilic polymers that contain a multiplicity of pores with diameters in the micrometer to millimeter range, enabling them to absorb tens of times their weight of aqueous fluids in just a fraction of a minute. SPH pores are interconnected in the hydrogel matrix such that absorbing fluid can move freely through the channels (capillaries), allowing them to swell much faster than conventional hydrogels that have the same swelling capacity.
  • a monomer, a crosslinker, a solvent (normally water), a surfactant (for foam stabilization), and a foaming aid are first mixed together, followed by the addition of an initiator.
  • a blowing agent is then added to the mixture for the generation of gas bubbles such as, for example, the generation of carbon dioxide.
  • foaming and polymerization also referred to as gelling
  • the viscosity of the reaction mixture increases and the bubbles being generated are trapped within the highly viscous polymer matrix.
  • the foaming resulting from simultaneous gelation and bubble formation continues until both processes are stopped.
  • the product takes the form of flexible foam. To remove residual monomer, non-reacted crosslinker, and initiator impurities, the flexible foam is washed thoroughly with water.
  • a water miscible alcohol such as, for example, ethanol
  • a final drying step is usually performed in an oven, preferably in a vacuum oven at low temperatures.
  • U.S. Patent No. 6,271,278 describes the preparation of various SPHs in detail. SPHs are also described by Chen, et al., inJ. Biomed. Mater. Res. 44:53-62 (1999).
  • Supe ⁇ orous hydrogels are generally prepared based on hydrophilic monomers, including acrylic acid and its salts, acrylamide, the potassium salt of sulfopropyl acrylate, hydroxyethyl acrylate, and hydroxyethyl methacrylate.
  • a desirable supe ⁇ orous hydrogel would possess high solvent abso ⁇ tion properties yet be able to withstand external forces such as tension, compression, and bending.
  • Some hydrogels have been prepared that have desirable swelling capacity and swelling rate properties. However, very high swelling supe ⁇ orous hydrogels are normally very loose after swelling and, when a small amount of pressure is applied, easily break apart.
  • Some hydrogels have also been prepared that have reasonable mechanical properties, such as strength, ruggedness, and resiliency. However, very strong supe ⁇ orous hydrogels absorb limited amounts of water and thus have undesirable swelling properties.
  • a preparation method for producing a hydrogel with both adequate swelling and mechanical properties is still lacking in the art.
  • This invention features a method for the preparation of a supe ⁇ orous hydrogel (SPH) in which its resulting physical and mechanical properties can be controlled by using a relatively simple ion-equilibration process, thereby producing a highly absorbent, yet structurally rugged and resilient, supe ⁇ orous hydrogel.
  • SPH supe ⁇ orous hydrogel
  • the invention features a method of forming a hydrogel that includes the steps of, a) combining at least one ethylenically-unsaturated monomer, a cross-linking agent, and an ionic polysaccharide to form a mixture, b) subjecting the mixture to polymerization conditions to form a hydrogel, and c) reacting the hydrogel with one or more cations under equilibrating conditions, where at least one cation is used that was not used in step a) or, if the same mixture of cations is used in steps a) and c), the ratio of cations used in these steps is different.
  • the hydrogel that is fo ⁇ ned by this method is a supe ⁇ orous hydrogel.
  • the mixture includes one or more members of the group consisting of: a diluent, a foam stabilizer, a foaming aid, a reductant, an oxidant, and a blowing agent.
  • the mixture includes all of the members of this group.
  • At least one of the cations used in step a) is monovalent and at least one of the cations used in step c) is divalent.
  • the monovalent cations include Na + , K + , or NH 4 + while divalent cations include Ca 2+ , Mg 2+ , Ba 2+ , Cu 2+ , Zn 2+ , Mn 2+ , or Fe 2+ .
  • the method includes an additional step of reacting the supe ⁇ orous hydrogel (SPH) fomied in step c) with one or more cations under equilibrating conditions where at least one cation is used that was not used in step c), or if the same mixture of cations is used as in step c), the ratio of cations used in this additional step is different.
  • the additional step includes reaction of the hydrogel with Ca 2+ , Cu 2+ , Zn 2+ , Ba 2+ , Mg + , Mn 2+ , Fe 2+ , Fe 3+ , Cr 3+ , Al 3+ , or Ce 4+ .
  • at least one of the cations reacted with said supe ⁇ orous hydrogel (SPH) formed in step c) has a valency of three or higher.
  • the polysaccharide of the invention can be, for example, salts of carboxymethylcellulose, alginate, hyaluronic acid, starch glycolate, carboxymethyl starch, dextran sulfate, pectinate, xanthan, carrageenan and chitosan.
  • the polysaccharide includes sodium salt of carboxymethylcellulose.
  • the ethylenically-unsaturated monomer of the invention can be, for example, (meth)acrylamide, N-isopropylacrylamide (NIP AM), N-cyclopropylacrylamide, diallyldimethylam onium chloride (DADMAC), 2-methacryloloxyethyl trimethylammonium chloride, N,N-dimethylaminoethyl acrylate, 2- hydroxyethyl acrylate (HEA), 2-hydroxyethyl methacrylate (HEMA), 2-hydroxypropyl methacrylate (HPMA), N- vinyl pyrrolidone (VP), (meth)acrylic acid (AA), salts of (meth)acrylic acid, salts and acids of esters of (meth)acrylic acid, amides of (meth)acrylic acid, N-alkyl amides of (meth)acrylic acid, salts and acids of N-alkyl amides of (meth)acrylic acid, itaconic acid
  • the mixture used in the formation of the hydrogel includes 2- hydroxyethyl acrylate as the ethylenically-unsaturated monomer.
  • the crosslinking agent of the invention can be, e.g., N,N'-methylenebisacrylamide, N,
  • N'-ethylenebisacrylamide poly(ethylene glycol) di(meth)acrylate, ethylene glycol di(meth)acrylate, ethyleneglycol diglycidyl ether, glycidyl methacrylate, polyamidoamine epichlorohydrin resin, trimethylolpropane triacrylate (TMPTA), piperazine diacrylamide, glutaraldehyde, epichlorohydrin, a crosslinking agent that includes one or more 1,2-diol structures, a crosslinking agent that includes one or more functionalized peptides, or a crosslinking agent that includes one or more functionalized proteins.
  • the mixture used in the formation of the hydrogel includes polyethylene glycol) diacrylate as the crosslinking agent.
  • the invention features a method of dehydrating a hydrogel, preferably a supe ⁇ orous hydrogel, by lyophilization, such that a water/SPH weight to weight ratio of from 0.005 to 0.1 is achieved.
  • the dehydrating method includes the steps of, a) freezing the supeiporous hydrogel to about -10°C, with a cooling rate of about 3°C per hour, b) maintaining the supe ⁇ orous hydrogel at about -10°C for 16 to 24 hours, c) lyophilizing the supe ⁇ orous hydrogel at about -10°C and at less than about 0.2 Torr for 60 to 80 hours, d) increasing the supe ⁇ orous hydrogel temperature to 10°C at a rate of about 3°C per hour, and e) maintaining the supe ⁇ orous hydrogel at 10°C and at less than about 200 mTorr for at least 12 hours.
  • the supe ⁇ orous hydrogel is prepared by a method of the present invention.
  • the invention features a method for the dehydration of a hydrogel, preferably a supe ⁇ orous hydrogel, such that a water/SPH weight to weight ratio of from 0.005 to 0.1 is achieved, where the method includes the steps of, a) displacing water contained in the hydrogel with a non-aqueous, water-miscible solvent or solvent mixture, and b) removal of said non-aqueous solvent or solvent mixture at a pressure of less than 50 Torr or by heat.
  • the non-aqueous solvent can be, e.g., methanol, ethanol, 1- propanol, 2-propanol, tetrahydrofuran, dioxane, formic acid, acetic acid, acetonitrile, nitromethane, acetone, or 2-butanone.
  • the non-aqueous solvent includes ethanol.
  • the supe ⁇ orous hydrogel is prepared by a method of the present invention.
  • a dehydrated supe ⁇ orous hydrogel of the invention can include a medicament, a nutritional substance, or a fertilizer and be in the form of a film, a sheet, a particle, a granule, a fiber, a rod, or a tube.
  • the dehydrated hydrogel additionally includes a controlled release system for any of these substances.
  • crosslinking agent is meant a molecule able to form a chemical bond to another substrate in the formation of a matrix.
  • monosaccharides polyhydric alcohols from three to ten or more carbon atoms containing either an aldehyde group (e.g., aldoses) or a keto group (e.g., ketoses), or masked aldehyde or keto groups, or derivatives thereof.
  • aldehyde group e.g., aldoses
  • keto group e.g., ketoses
  • Examples of monosaccharide units are the D and L configurations of glyceraldehyde, erythrose, threose, ribose, arabinose, xylose, lyxose, allose, altrose, glucose, mannose, gulose, idose, galactose, talose, dihydroxyacetone, ervthrulose, ribulose, xylulose, puscose, fructose, sorbose and/or tagatose.
  • monosaccharides also include those monosaccharide deoxy sugars, such as, for example, fucose, rhamnose, and digitoxose; deoxyamino sugars such as, for example, glucosamine, mannosamine, galactosamine; deoxyacylamino sugars such as, for example, N-acetylglucosamine, N-acetylmam osamine, and N-acetylgalactosamine; and aldonic, aldaric and/or uronic acids such as, for example, gluconic acid or glucuronic acid.
  • monosaccharide deoxy sugars such as, for example, fucose, rhamnose, and digitoxose
  • deoxyamino sugars such as, for example, glucosamine, mannosamine, galactosamine
  • deoxyacylamino sugars such as, for example, N-acetylglucosamine, N-acetyl
  • Monosaccharides also include ascorbic acid, amino acid-carrying monosaccharides and monosaccharides which carry lipid, phosphatidyl or polyol residues.
  • peptide is meant a molecule that contains from 2 to 100 natural or unnatural amino acid residues joined by amide bonds formed between a carboxyl group of one amino acid and an amino group from the next one.
  • functionalized peptide refers to those peptides that have at least two groups suitable for carrying out a crosslinking reaction. These groups include olefins, carbonyls, esters, acyl halides, alkyl halides, and the like.
  • protein is meant a molecule that contains greater than 100 natural or unnatural amino acid residues joined by amide bonds formed from a carboxyl group of one amino acid and an amino group from the next one.
  • functionalized protein refers to those proteins that have at least two groups suitable for carrying out a crosslinking reaction. These groups include olefins, carbonyls, esters, acyl halides, alkyl halides, and the like.
  • polysaccharide is meant to include any polymer of monosaccharides, or mixtures of polymers of monosaccharides, or salts therein, and includes disaccharides, oligosaccharides, etc.
  • Polysaccharides include starch, carrageenan, xanthan, dextran, cellulose, chitosan, glycogen, hyaluronic acid, alginic acid, pectin and glycosylaminoglycans.
  • the polysaccharide of this invention may be unmodified or modified and the term polysaccharide is used herein to include both types.
  • modified polysaccharide it is meant that the polysaccharide can be derivatized or modified by typical processes known in the art, e.g., esterification, etherification, grafting, oxidation, acid hydrolysis, cross-linking and/or enzyme conversion.
  • modified polysaccharides include esters such as the acetate and the half-esters of dicarboxylic acids, particularly the alkenylsuccinic acids; ethers, such as hydroxyethyl and hydroxypropyl starches and starches reacted with hydrophobic cationic epoxides; starches oxidized with hypochlorite; starches reacted with cross-linking agents such as phosphorous oxychloride, epichlorohydrin or phosphate derivatives prepared by reaction with sodium or potassium orthophosphate or tripolyphosphate and combinations thereof.
  • hydrogel is meant a crosslinked polymer network that is not soluble in water but swells to an equilibrium size in the presence of water.
  • silica hydrogel is meant a hydrogel that has interconnecting pores.
  • an ethylenically-unsaturated monomer is mixed with several ingredients, including a crosslinker and a certain amount of an ionic polysaccharide, in a polymerization reaction.
  • the mixture can also include one or more co-monomers, diluents, surfactants, foaming aids, initiators, and blowing agents.
  • the mixture can be polymerized by any method known to those skilled in the art, as described by Odian in Principles of Polymerization, 3 r Edition (1991), Wiley-Interscience. Polymerization techniques can include, for example, solution, suspension, microsuspension, inverse suspension, dispersion, emulsion, microemulsion, and inverse emulsion polymerization.
  • the ethylenically-unsaturated monomer used to make the supe ⁇ orous hydrogel of the invention can be (meth)acrylic acid, salts of (meth)acrylic acid, esters of (meth)acrylic acid, salts and acids of esters of (meth)acrylic acid, amides of (meth)acrylic acid, N-alkyl amides of (meth)acrylic acid, salts and acids of N-alkyl amides of (meth)acrylic acid, N-vinyl pyrrolidone, acrylamide, acrylamide derivatives (e.g., N-1-propylacrylamide, N- isopropylacrylamide), methacrylamide, methacrylamide derivatives (e.g., N- cyclopropylmethacrylamide), and the like, and mixtures thereof.
  • Preferred monomers include acrylamide (AM), N-isopropylacrylamide (NIP AM), 2-hydroxyethyl acrylate (HEA), 2-hydroxyethyl methacrylate (HEMA), 2-hydroxypropyl methacrylate (HPMA), N-vinyl pyrrolidone (VP), acrylic acid (AA), sodium acrylate (Na + AA), potassium acrylate (K + AA), ammonium acrylate (NH 4 + AA), methacrylic acid and its salts, N, N-dimethylaminoethyl acrylate, diallyldimethylammonium chloride (DADMAC), 2-acrylamido-2-methyl-l- propanesulfonic acid (AMPS), 3-sulfopropyl acrylate, potassium salt (SPAK), 3-sulfopropyl methacrylate, potassium salt (SPMAK), 2-(acryloyloxy)ethyltrimethyl-ammonium methyl sulfate (ATMS), inorganic salt
  • the concentration of monomer is from about 5% to about 50% (v/v) of the total reaction mixture volume when used as the primary monomer and from about 0.5% to about 10% (v/v) of the total reaction mixture volume when used as a secondary co-monomer.
  • the reaction mixture includes 2-hydroxyethyl acrylate (HEA) as a primary monomer and a 50%) (w/w) aqueous solution of 3-sulfopropyl acrylate, potassium salt as a co-monomer in a 4:1 (v/v) ratio, respectively, the combined volume of the two accounting for about 23% (v/v) of the total reaction mixture volume.
  • HOA 2-hydroxyethyl acrylate
  • Crosslinking agents can be glutaraldehyde, epichlorohydrin, and degradable crosslinking agents including crosslinkers containing 1,2-diol structures (e.g., N,N'- diallyltartardiamide and ethylene glycol dimethacrylate), functionalized peptides and proteins (e.g., albumin modified with vinyl groups), ethylene glycol di(meth)acrylate, frimethylolpropane triacrylate (TMPTA), N,N'-methylenebisacrylamide (BIS), and piperazine diacrylamide.
  • 1,2-diol structures e.g., N,N'- diallyltartardiamide and ethylene glycol dimethacrylate
  • functionalized peptides and proteins e.g., albumin modified with vinyl groups
  • TMPTA frimethylolpropane triacrylate
  • BIOS N,N'-methylenebisacrylamide
  • Multiolefinic crosslinking agents containing at least two vinyl groups such as ethylene glycol di(meth)acrylate, poly (ethylene glycol) di(meth)acrylate, frimethylolpropane triacrylate (TMPTA), N,N'-methylenebisacrylamide (BIS), piperazine diacrylamide, crosslinkers containing 1,2-diol structures and two vinyl groups (e.g., N,N'- diallyltartardiamide or ethylene glycol dimethacrylate) are preferred.
  • a most preferred crosslinking agent is poly(ethylene glycol) diacrylate.
  • the (v/v) ratio of crosslinker to monomer is from about 0.01/100 to about 1/10. Most preferably, the (v/v) ratio of crosslinker to monomer is from about 1/100 to 1/10.
  • foam stabilization can be accomplished by physical or chemical means.
  • a rapid cooling or hot drying (for example, flash drying at a high temperature under an inert atmosphere) process can be used to stabilize the foam that has been produced by a gas blowing technique.
  • a surfactant can be used to stabilize the foam until the beginning of the gelling process.
  • Useful surfactants include Triton surfactants, Tween and Span surfactants, Pluronic ® surfactants (poly(ethylene oxide)- poly(propylene oxide)-poly(ethylene oxide) tri-block copolymers) (BASF), Silwet ® surfactants (OSi Specialties Inc.), sodium dodecyl sulfate (Bio-Rad Laboratories), albumin (Sigma Chemical Company), gelatin, or combinations thereof.
  • Pluronic F127 PF127
  • Surfactant concentrations in the range of about 0.2% to about 2% (w/v) of the total solution were found to be adequate.
  • the surfactant concentration is in the range of about 0.4%) to about 1%> (w/v).
  • the surfactant concentration is about 0.7% (w/v)
  • Any gas blowing technique for example, chemical or mechanical, can be used to prepare the supeiporous hydrogels of the invention. Because of the foaming technique used in the preparation of these hydrogels, they may also be called hydrogel foams. In the synthesis of a supe ⁇ orous hydrogel by a gas blowing technique, foaming and polymerization have to occur simultaneously, making it important to control the timing of these reactions. Inorganic carbonates, such as sodium carbonate, potassium carbonate, potassium bicarbonate, or, most preferably, sodium bicarbonate, can be used as a blowing agent.
  • Polymerization may be initiated by any polymerization-initiator system which is suitable for the polymerization of unsaturated monomers in the homogeneous or heterogeneous phase.
  • initiator systems that may be used in the process according to the present invention are those known to the person skilled in the art of polymer chemistry.
  • such initiators are preferably free- radical or free-radical forming compounds or mixtures of substances, such as for example hydroperoxides, preferably cumyl hydroperoxide or tert.-butyl hydroperoxide, organic peroxides, preferably dibenzoyl peroxide, dilauryl peroxide, dicumyl peroxide, di-tert.
  • inorganic peroxides preferably potassium persulfate, potassium peroxydisulfate or hydrogen peroxide
  • azo compounds preferably azobis(isobutyronitrile), l,l'-azobis(l-cyclohexane nitrile), 4,4'- azobis(4-cyanovaleric acid) or triphenyl-methylazobenzene
  • redox systems preferably mixtures of peroxides and amines, mixtures of peroxides and reducing agents, optionally in the presence of metal salts and/or chelating agents.
  • the initiator systems can be pure or in the form of mixtures of two, three or more different initiator systems.
  • portions of the initiator system are added to the reaction separately in solid, liquid or gaseous form.
  • This procedure is particularly suitable for redox initiator systems.
  • Li the present invention preferably a combination of an oxidant and a reductant (a redox pair) is used as an initiator.
  • a redox pair preferably a combination of ammonium persulfate (APS) and N,N,N',N'- tetramethylethylenediamine (TEMED) is used.
  • APS ammonium persulfate
  • TEMED N,N,N',N'- tetramethylethylenediamine
  • the pore size of the supe ⁇ orous hydrogels prepared by the foaming technique is usually larger than 100 ⁇ m, and it can easily reach the millimeter range. Usually, the pores are so large that they are visible with the unaided eye.
  • the ionic polysaccharide used can be any polysaccharide that includes negatively/positively charged groups that can counter the positive/negative charge of a cation/ anion.
  • a primary cation is initially provided with the ionic polysaccharide of the supe ⁇ orous hydrogel formulation, with the polysaccharide playing a critical role in the process of subsequent ion-equilibration(s).
  • the polysaccharide is chosen from the list that includes sodium carboxymethylcellulose, sodium starch glycolate, sodium carboxymethyl starch, dextran sulfate, chitosan, hyaluronic acid, xanthan, carrageenan, gellan, sodium alginate, and sodium pectinate.
  • the polysaccharide is sodium carboxymethylcellulose.
  • the ratio of polysaccharide to total solution can be in the range of 0.1-10%) w/v.
  • the range is 0.2-5% w/v.
  • the range is 0.2-1.5% w/v.
  • Ion equilibration is a process by which ion exchange happens within the substrate structure.
  • the exchange process may take place between any kinds of ions of different valences (e.g., monovalent, divalent, trivalent or higher).
  • 2-valent cations within the substrate can partially be replaced by 3-valent cations or vice versa.
  • the product contains equilibrium amounts of two or more cations.
  • the equilibration just described results in considerable change in substrate properties.
  • sodium salt of carboxymethylcellulose is soluble in water, while its calcium-treated derivative is water-insoluble. Therefore, a simple partial replacement of sodium with calcium cation makes the final polymer sparingly soluble or insoluble in water.
  • the general process of dramatically changing the properties of a substrate based on ion- exchange can also be applied to a supe ⁇ orous hydrogel formulation of the invention.
  • a hydrogel substrate can originally contain ions or can be ionized after its formation.
  • a salt, ionic monomer, an ionic polymer, or any other ionic ingredient can provide the original or primary cation.
  • This original cation is called primary, since it has to be partially replaced by another cation, i.e. secondary.
  • the equilibrium mixture of primary and secondary cations can also be equilibrated with the third cation, i.e. tertiary cation and so on.
  • the process of ion-equilibration can be repeated with a number of different cations.
  • a simple salt, ionic monomer, ionic polymer or another ion source can provide the secondary or tertiary cation.
  • the ion-equilibration process can take place in an aqueous or a mixed aqueous/alcoholic medium, where the ions can move with freedom.
  • a polysaccharide-containing supe ⁇ orous hydrogel can be immediately placed into an aqueous or mixed aqueous/alcoholic solution that includes any 2-valent cation, 3-valent cation or mixture of 2-, 3- or higher- valent cations like cerium.
  • the two-valent cation is Ca , Ba , Mg , Cu , Zn , Mn , or Fe 2+ .
  • the 2-valent cation is Ca 2+ .
  • the ion-exchange process between monovalent and two-valent cations is rapid and swelling of the hydrogel occurs.
  • the ion-equilibrated supe ⁇ orous hydrogel may be retreated with a solution that includes a tertiary cation.
  • the 3-valent cation is iron or aluminum.
  • the supe ⁇ orous hydrogel is placed into medium that includes a trivalent cation and cation equilibration occurs rapidly.
  • the hydrogel is left in the solution for aperiod of time, preferably from 0.5 hour to 24 hours.
  • the ion-equilibrated hydrogel is then thoroughly washed with pure water, washed with a non-aqueous, water-miscible solvent, and dried out in an oven or in a vacuum oven.
  • the purified supe ⁇ orous hydrogel can be dried out in an oven/vacuum oven or by a lyophilization technique. Examples of how the ion-equilibration process can considerably change the final physical and mechanical properties of the supe ⁇ orous hydrogel produced are shown in Table 1.
  • Cation provided by the polysaccharide that is sodium salt of carboxymethylcellulose b) Cation provided by hydrated calcium chloride. c) Cation provided by hydrated aluminum chloride or hydrated ferric chloride.
  • the method includes the steps of, a) displacing water contained in the hydrogel matrix with a non-aqueous, water-miscible solvent or solvent mixture through a series of washings, and b) removal of said non-aqueous solvent or solvent mixture at a pressure of less than 50 Torr or by heat.
  • the non-aqueous solvent can include methanol, ethanol, 1-propanol, 2- propanol, tetrahydrofuran, dioxane, formic acid, acetic acid, acetonitrile, nitromethane, acetone, or 2-butanone.
  • the non-aqueous solvent includes ethanol.
  • a preferred method includes the steps of, a) freezing the supe ⁇ orous hydrogel sample from about 23°C to about -10°C with a cooling rate of about 3°C per hour, b) maintaining the sample at about -10°C for 16 to 24 hours, c) lyophilizing the sample at about -10°C and at less than about 0.2 Torr for 60 to 80 hours, d) increasing the sample temperature to 10°C at a rate of about 3°C per hour, and e) maintaining the sample at 10°C and at less than about 200 mTorr for at least 12 hours.
  • the dehydrated supe ⁇ orous hydrogels of the present invention rapidly swell to a relatively large size when placed in contact with aqueous fluids, yet remain mechanically strong in their swollen state. Taking advantage of these properties, these hydrogels can be useful as drug delivery systems (DDSs), as described by Park, et al., in Biodegradable
  • DDSs release pharmaceutical agents from specific locations in the body over specific periods of time. Without additional measures taken to retard its passage through the alimentary canal, there is usually a ten hour limit for the abso ⁇ tion through the lining of the small intestine of an orally administered drug.
  • some drugs are preferentially absorbed in certain regions in the gastrointestinal tract (GI), with many preferentially absorbed in the upper GI. In these cases, it is desirable to prolong the residence of a DDS in the upper GI tract (gastric retention) to enhance drug absorbance.
  • GI gastrointestinal tract
  • Other hydrogels have also been used for this pu ⁇ ose, such as those described by Park, et al., in U. S. Patent No. 6,271,278, which is hereby inco ⁇ orated by reference.
  • Drug delivery can involve implanting a controlled release system within a matrix of a dehydrated supe ⁇ orous hydrogel of the invention.
  • This in turn, would be contained in a capsule (e.g., a gelatin capsule) or similar housing system that can be eroded by the acidic conditions in the stomach.
  • the gastric retention of supe ⁇ orous hydrogels is based on their fast swelling property. Once a supe ⁇ orous hydrogel of the invention is exposed to gastric fluid, it rapidly swells to its maximum swelling capacity, typically in less than ten minutes.
  • supe ⁇ orous hydrogels that swell to a diameter of greater than 2 cm at low pH conditions are desirable as they are then unable to pass through the pylorus sphincter, ensuring prolonged residence in the stomach and better abso ⁇ tion of the drug through the upper GI.
  • hydrogels of the invention can have a variety of applications including, for example, tissue engineering, vascular surgery (e.g., angioplasry) and drainage (e.g., from the kidney).
  • Devices prepared using hydrogels of the invention can include vascular grafts, stents, catheters, cannulas, plugs, constrictors, tissue scaffolds, and tissue or biological encapsulants, and the like.
  • the materials may be applied to any use which requires a porous hydrogel material, particularly with an open pore structure.
  • the materials are useful as matrices or scaffolds into which cells can migrate, the cells being compatible therein and growing to achieve their intended function, such as in tissue replacement, eventually replacing the matrix depending on its biodegradability.
  • the materials can be used to provide matrices already bound to cells, which may then be surgically implanted into a body. Further, the materials can be used as wound healing matrix materials, as matrices for in vitro cell culture studies or uses similar thereto.
  • the stable structure of the materials of the invention provides ideal cell culture conditions.
  • the materials of the invention may also have application in cell transplantation, including for hepatocytes (see, D. J. Mooney, P. M. Kaufmann, K. Sano, K. M. McNamara, J. P. Vacanti, and R. Langer, "Transplantation of hepatocytes using porous biodegradable sponges," Transplantation Proceedings, 1994, 26:3425-3426; D. J. Mooney, S. Park, P. M. Kaufmann, K. Sano, K. McNamara, J. P. Vacanti, and R. Langer, "Biodegradable sponges for hepatocyte transplantation," Journal of Biomedical Materials Research, 1995, 29:959-965), chondrocytes and osteoblasts (see, S.
  • Smooth muscle cells may readily adhere to the material prepared according to the invention and create three-dimensional tissues especially if appropriate cell adhesion ligand are coupled to the hydrogel structure within these porous structures; thus, they provide a suitable environment for cell proliferation.
  • these materials have potential to inco ⁇ orate growth factors.
  • GTR guided tissue regeneration
  • progenitor cells responsible for tissue regeneration reside in the underlying healthy tissue and can be induced to migrate into a defect and regenerate the lost tissue.
  • a critical feature of materials for GTR is the transport of cells into the material, a property which is dictated by the pore size distribution and pore continuity, i.e., interconnectivity. The material must allow the desired cells to invade the material while preventing access to other cell types. Because of the absorbent properties of the hydrogels of the invention they are very suitable for use in absorbent articles, and especially disposable absorbent articles.
  • absorbent article herein is meant a consumer product which is capable of absorbing significant quantities of water and other fluids (i.e., liquids), like body fluids.
  • absorbent articles include disposable diapers, sanitary napkins, incontinence pads, paper towels, facial tissues, and the like.
  • Hydrogels of the invention can also be useful for protecting, holding or transplanting growing plants in the fo ⁇ n of seeds, seedlings, tubers, cuttings, nursery stock, roots, transplants and the like. These hydrogels can aid a growing plant, either alone or in combination with fertilizer, agricultural modified minerals, and the like uniformly dispersed throughout.
  • Examplel The formation of a hydroxyethylaaylate-based superporous hydrogel using an ion-equilibration process (Multiple ions ofNa + , Ca and Fe + ; Multiple Treatments).
  • the foam was removed from the tube and placed into an aqueous solution of calcium chloride (1 :200 (w/v) of hexahydrated calcium chloride in distilled water). The suspension was incubated for 2 hrs.
  • the calcium-treated supe ⁇ orous hydrogel was immersed into an aqueous ferric chloride solution (1:300 (w/v) of hexahydrated ferric chloride in distilled water). The suspension was incubated for another 2 hrs.
  • Example 2 The formation of a hydroxyethylacrylate-based superporous hydrogel using an ion-equilibration process (Multiple ions ofNa + , Ca andAl + ; Single Treatment).
  • Example 2 Similar to Example 1 except the foam was removed from the tube and placed into a mixture of an aqueous solution of hexahydrated calcium chloride (1:200 (w/v)) and hexahydrated aluminum chloride (0.5: 200 (w/v)). The suspension was incubated for 2 hrs.
  • Example 3 The formation of a hydroxyethylacrylate-based superporous hydrogel using an ion-equilibration process (Midtiple ions ofNa + and Fe 3+ ; Single Treatment).
  • Example 2 Similar to Example 1 except the foam was removed from the tube and placed into an ethanolic aqueous solution of hexahydrated ferric chloride (1:200 (w/v)). The ethanol/ water ratio was 1/3 v/v. The suspension was incubated for 2 hrs.
  • the ion-equilibrated supe ⁇ orous hydrogel was thoroughly washed with de-ionized water (100 niL, five to ten times) until all impurities were removed.
  • the purified ion-equilibrated supe ⁇ orous hydrogel was then dehydrated by treating it with ethyl alcohol (100 mL, one to three times), followed by drying in an air-forced oven at 40°C.
  • the purified ion-equilibrated supe ⁇ orous hydrogel may directly be dried out in an oven or vacuum oven.
  • the purified ion-equilibrated supe ⁇ orous hydrogel can be freeze-dried using the following lyophilization schedule: a) freezing the supe ⁇ orous hydrogel from room temperature to -10°C, with a freezing rate of-3°C/hr., b) keeping the sample at a temperature of-10°C for 24 hrs., d) lyophilizing at 10 - 100 mTorr for 72 hrs., e) raising the temperature to 10°C at a rate of 3°C/hr., and f) drying at 10°C for 24 hrs.

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